Shipping pallet sleeve system and methods

ABSTRACT

Sleeve pallet 10 is constructed from corrugate are disclosed. The sleeve pallet 10 includes a series of stringers 12 secured to an upper deck 14 and/or collar 16. When bonded to an upper deck 14, the upper deck 14 is bonded to and supports a collar 16. The collar 16 defines a peripheral flange 40. The peripheral flange 40 retains a sleeve over the collar 16 and/or upper deck 14 of the sleeve pallet 10. A cap 60 can be provided to cover and retains goods within the cavity 82 defined by the sleeve pallet 10. Before assembly, the flange 40 of the collar 16, the sleeve 18, and, when used, the cap 60 may be secured together by straps in a collapsed configuration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority and benefit of U.S. Provisional PatentApplication No. 62/861,211 filed 13 Jun. 2019, which is herebyincorporated by reference in its entirety herein.

BACKGROUND OF THE INVENTION Field of the Invention

This disclosure relates to shipping pallets, and, more particularly, topallets fabricated from corrugated fiberboard as sleeve pallets.

Background of the Related Art

Pallets and skids, collectively herein “pallets”, in various forms havebeen an important part of shipping freight since the 1930's.Historically, pallets were constructed of wood. Wooden shipping palletsare relatively costly, heavy and susceptible to damage. Wood continuesto dominate the pallet market today. In recent history, lighter plasticpallets and more durable metal pallets have been developed. However,both of these options tend to be more costly.

The conditions under which most pallets are used typically results indamage that can render the pallet unusable after a short amount of time.Plastic pallets, when damaged, are typically not repairable. Woodpallets are regularly repaired, but this results in a huge amount ofwaste wood that is relatively difficult to dispose of. Metal palletstend to better resist damage but their price point and weight is toohigh to be usable in typical shipping applications. Industries arealmost always looking for ways to save costs. Accordingly, a need existsfor lower cost, lightweight pallets. As a result, the past few decadeshave seen shipping pallets developed from other materials. One suchmaterial is corrugated fiberboard. Corrugated fiberboard, in certainaspects, may include a fluted corrugated sheet in combination with oneor two flat linerboards formed of cellulose based material(s).Corrugated fiberboard is a strong renewable material that is one of themost widely recycled materials in the world. Corrugated fiberboardgenerally has a high tensile strength but its strength under compressionis most significant when applied along the longitudinal axis of theflutes. The flutes of the corrugated fiberboard provide a columnarstructure along their longitudinal axis that is strong in compression,in certain aspects. Accordingly, it may be advantageous to configurecertain components of corrugate pallets with the flutes of thecorrugated fiberboard oriented vertically.

One particular type of shipping pallet system incorporates a sleeve orwall that extend upward from a shipping pallet's top deck. These wallsare configured to retain goods during the shipping of products onshipping pallets. Such pallets can also be utilized as long term storagesolutions as they can be provided with re-closable lids to allow foraccess to their contents and the recovering of the goods after suchaccess. These sleeve pallet systems are typically manufactured from acombination of materials to meet the cost, strength and durabilityrequirements of shipping goods. The mix materials generally includewood, corrugate or plastic, and nails or staples. Such a mix ofmaterials complicates the recycling process in that to varying degreesthe pallets need to be disassembled and the various materials to permitrecycling. This increases costs and reduces the likelihood of theexisting sleeve pallets systems from being fully recycled.

Therefore, a need exists for sleeve systems for shipping pallets thatsolely utilize components formed from corrugated fiberboard and othercellulose materials and adhesives that allow the entire pallet system tobe recycled without the need for time consuming and expensivedisassembly.

Similarly, large shipping boxes, commonly referred as Gaylords, havebeen sized to correspond to the size of the deck of a pallet as well asbeing configured to be shipped on pallets. However, these boxes canstill require stretch wrapping or other means of securing the boxes tothe pallets. This can increase the costs of shipping as well asrecycling as a variety of disparate materials may have to be used. Whennot secured, the boxes have an increased risk of being displaced fromthe pallet and having the goods contained therein damaged duringshipping.

Therefore, a need exists for a pallet designs and methods for efficientmanufacturing of corrugated fiberboard components to secure a goods on apallet that does not compromise the strength or durability of thecomponents and are also cost effective.

BRIEF SUMMARY OF THE INVENTION

Apparatus and methods in accordance with the present inventions mayresolve many of the needs and shortcomings discussed above and mayprovide additional improvements and advantages that may be recognized bythose skilled in the art upon review of the present disclosure.

In certain aspects, an apparatus for the shipping and storage of goodsis provided. The apparatus having a plurality of stringers, a collar anda sleeve. In certain aspects, a upper deck may also be provided. Theupper deck including one or more corrugate sheets. The stringers areadhesively secured to a lower surface of the upper deck and/or thecollar. The collar is a single corrugate sheet defining a peripheralflange. In certain aspects, a lower surface of collar adhesively securedto an upper surface of the upper deck. The sleeve may include one ormore corrugate sheets. A lower portion of the sleeve received within theperipheral flange of the collar. The apparatus can include a reinforcinginsert positioned on an upper surface of the collar. The reinforcinginsert adhesively secured to the upper surface of the collar. In certainaspects, the apparatus can further include a cap made from a singlecorrugate sheet and defining a peripheral cap flange, the cap receivedover an upper portion of the sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an exemplary shipping palletsleeve system in accordance with aspects of the present inventions;

FIG. 2A illustrates a perspective view of an exploded exemplary shippingpallet sleeve system of FIG. 1 in accordance with aspects of the presentinventions;

FIG. 2B illustrates a detailed partial perspective view of an exemplarypallet of the shipping pallet sleeve system in accordance with aspectsof the present inventions

FIG. 3 illustrates a perspective view of an exploded exemplary shippingpallet sleeve system in a collapsed configuration in accordance withaspects of the present inventions;

FIG. 4 illustrates a perspective view of an exemplary shipping palletsleeve system in a collapsed configuration in accordance with aspects ofthe present inventions;

FIG. 5A illustrates a perspective view of an exemplary upper deck in acollapsed configuration and FIG. 5B illustrates in detail a portion ofFIG. 5A in accordance with aspects of the present inventions;

FIG. 6 illustrates a perspective view of an exploded exemplary upperdeck in accordance with aspects of the present inventions;

FIG. 7A illustrates a perspective view of an exemplary collar inaccordance with aspects of the present inventions.

FIG. 7B illustrates a perspective view of another exemplary collar inaccordance with aspects of the present inventions;

FIG. 7C illustrates a perspective view of another exemplary collar inaccordance with aspects of the present inventions;

FIG. 7D illustrates a perspective view of an exemplary cap in a foldedconfiguration in accordance with aspects of the present inventions;

FIG. 8A illustrates a side view of an exemplary sleeve in accordancewith aspects of the present inventions; and

FIG. 8B illustrates a side view of an exemplary sleeve in accordancewith aspects of the present inventions.

All Figures are exemplary and selected for explanation of the basicteachings of the present inventions only. Extensions of the Figures withrespect to number, position, relationship and dimensions of the parts toform the preferred implementation will be explained or will be withinthe skill of the art after the following description has been read andunderstood. Further, the exact dimensions and dimensional proportions toconform to specific force, weight, strength, and similar requirementsfor various implementations will likewise be within the skill of the artafter the following description has been read and understood.

Where used in the various Figures, the same numerals designate the sameor similar elements. Furthermore, when the terms “top,” “bottom,”“right,” “left,” “forward,” “rear,” “first,” “second,” “inside,”“outside,” and similar terms are used, the terms should be understood inreference to the orientation of the implementations shown in thedrawings and are utilized to facilitate description thereof. Use hereinof relative terms such as generally, about, approximately, essentially,may be indicative of engineering, manufacturing, or scientifictolerances such as ±0.1%, ±1%, ±2.5%, ±5%, or other such tolerances, aswould be recognized by those of ordinary skill in the art upon study ofthis disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The Figures generally illustrate exemplary implementations of a sleevepallet 10 for the containment and shipping of goods that include aspectsmanufactured in accordance with the present inventions. The particularlyillustrated implementations of sleeve pallet 10 has been chosen for easeof explanation and understanding of various aspects of the presentinventions. It will be understood that the term shipping pallet shallinclude other similar products used for shipping cargo such as skids,box pallets, shipping crates, and the like that may use the elements ofsleeve pallet 10 or other structurally similar components manufacturedin accordance with methods of the present teachings. That said, theillustrated implementations are not meant to limit the scope of coveragebut, instead, to assist in understanding the context of the languageused in this specification and in the appended claims. Accordingly, theappended claims may encompass variations of sleeve pallet 10 that differfrom the illustrated implementations.

The present inventions provide methods for the manufacture of a sleevepallet 10 and components thereof for use in shipping, retail sales andstorage applications. The sleeve pallets 10 in accordance with thepresent inventions are predominately manufactured from corrugatedfiberboard or corrugated plastic, both of which are referred tocollectively hereinafter as corrugate. As noted below, these sheets whenlaminated can include alternative materials in certain layers of thelaminate. An exemplary sleeve pallet 10 is illustrated in FIG. 1 and, inan exploded view, in FIG. 2. The illustrated sleeve pallet 10 isgenerally configured to support a load that may consist of various itemsindividually, boxed or otherwise packaged. Sleeve pallet 10 aregenerally configured to be lifted by forklift and, in variousimplementations, may be particularly configured to be placed, forexample, in a storage rack, cargo hold, storage bay, railroad car, ortruck trailer. Sleeve pallets 10 are typically configured as either a2-way or as a 4-way pallet. The sleeve pallet 10, as illustrated,includes an upper deck 14 and two or more stringers 12 secured to theupper deck 14, a collar 16, which may be integral with the upper deck14, a sleeve 18, and a cap 20. The sleeve pallet 10 is configured toreceive and support a load of goods on the upper deck 14. The sleeve 18is generally configured to retain the goods on the upper deck 14. Thestringers 12 support the upper deck 14. Upper deck 14 may be singlesolid piece of sheets of corrugate, two or more laminated sheets ofcorrugate, or may include two or more deck boards, in variousimplementations. For example, the upper deck 14 may include between 1and 6 individual deck boards secured to the upper surface of thestringers 12 but may include more deck boards in certainimplementations. The Upper deck 14 is typically bonded to the stringers12 with an adhesive 50. The collar 16 is adhesively bonded to the upperdeck 14 or may be integral with the sheet of corrugate that forms theupper deck 14. The corrugate sheets 40 of the upper deck 14 and collar16, when both elements are present, are bonded with an adhesive 50,illustrated in FIG. 6, between the linerboards of the corrugate sheets30. If the upper deck 14 are separate components, they are adhesivelybonded to one another to retain the relative position of the collar 16on the upper deck 14. Upper deck 14 and/or collar 16 in combination withsleeve 18 may be generally configured to meet certain volumetriccapacity requirements, to support and retain a specific load, or tosupport and retain a specific cargo.

Stringers 12 are generally elongated support elements having a generallyrectangular side profile that support the upper deck 14 and collar 16.Stringers 12 have a generally flat upper surface 32 and lower surface34, and the upper and lower surfaces of the stringer may include shapedcutouts to receive various components of the sleeve pallet 10. Thestringers 12 may provide notches 22 for the tines of a forklift or for apallet jack underneath the upper deck 14. Notches 22 are configured toreceive the tines of a forklift to enable the lifting pallet 10including materials placed upon upper deck 14 and extend from one sideof the stringer 12 through to the other side, in variousimplementations. The notches 22 of adjacent stringers 12 of a sleevepallet 10 may be aligned with one another to permit the passage of thetines of a forklift and/or, in certain configurations, a pallet jackthrough the side of sleeve pallet 10 to provide more flexible access andutility in sleeve pallet 10. The flat upper surface 32 of stringers 12may provide the surface area necessary to securely bond the stringers 12to the upper deck 14 or the collar 16.

A lower deck 22 may also be included in sleeve pallet 10, in certainimplementations. The two or more stringers 12 are generally securedbetween the upper deck 14 and the lower deck 22, as illustrated. Thelower deck 22 can be a single solid piece of corrugate or multiplepieces of laminated corrugate. In other implementations, the lower deck22 may be composed of fiberboard or other material. A typical lower deck22 will include 3 or 4 separate boards configured to permit the sleevepallet 10 to be used with a pallet jack that, for example, allows a userto manually raise and move a loaded sleeve pallet 10 around a warehouse.In one implementation, the sleeve pallet 10 may be manufactured solelyor predominantly from recyclable materials, such as, for example, paper,corrugate, fiberboard and other cellulose based products that arepreferably re-pulpable for ease of recycling.

The sleeve pallets 10 in accordance with the present inventions aretypically made from corrugate sheets 30. The corrugate sheets 30 aretypically corrugated fiberboard or corrugated plastic. When corrugatedfiber board, the corrugate sheets 30 may utilize, for example, “A”, “B”,“C”, “E”, “F” or “micro-flute” configurations as well as other fluteconfigurations that may be used in the paper industry, as would bereadily recognized by those of ordinary skill in the art upon study ofthis disclosure. Similarly, the corrugate sheets 30 may be single wall,double wall or triple wall as used in the paper industry, as would bereadily recognized by those of ordinary skill in the art upon study ofthis disclosure. It will be appreciated that the fluted medium strengthalong the load-bearing axis typically increases with flute density. Thechoice of flute density as well as the materials and choice of adhesive50 included in the corrugate sheets 30 will depend upon the specificdesign requirements for the sleeve pallet 10 including the loads to becarried.

The stringers 12 may include a plurality of corrugated sheets 30 andstringers 12 may include one or more solid fiberboard layers for addedstrength. The sleeve 18 is also typically configured from one or morecorrugated sheets 30. The corrugate sheets 30 and, if present,alternative materials are secured together, for example, with anadhesive 50 between the linerboards of the corrugate sheets 30. Specificcompositions for the laminate used in stringer 12 may be selected basedon the particular design requirements for stringer 12 including, forexample, forces to be supported by stringers 12. Similarly, theorientation of the flutes in the corrugate of stringers 12 as well asthe geometric configuration of the corrugate may be selected based uponspecific design requirements for the stringers 12. In certainconfigurations of stringers 12, the flutes will be vertically orientedand the flutes off majority of the layers will be parallel to oneanother in the vertical orientation. Similarly in certain configurationsfor sleeve 18, the flutes will also be vertically oriented to maximizethe vertical load that can be supported.

The stringer 12 may be sized to have a length substantially the same asthe desired length of the sleeve pallet 10. This will frequentlycorrespond to the length of the upper deck 14. The width of thestringers 12 is generally between about 1.5 inches (3.81 cm) and about4.0 inches (10.16 cm). Certain design requirements may require thatstringer 12 have a greater strength. Stringers 12 may be strengthened byincreasing in number of layers of corrugate sheet 30, by changing thematerial of the corrugate sheet 40, through the elimination of notches18, and/or by the addition of solid fiberboard sheet or sheets of otherstrong materials into the laminate.

When present, as shown in FIG. 6, an upper deck 14 is bonded the collar16 with an adhesive 50. In certain embodiments, the upper deck 14 andthe collar 16 may functionally be a single component formed from asingle corrugate sheet 30. Regardless, the collar 16 is typically formedfrom a single corrugate sheet 30 but in certain configurations may beformed from two or more corrugate sheets 30. The collar 16 is generallyconfigured to retain the sleeve 18 on its upper surface and to support aload resting on its upper surface. The collar 16 is typically square orrectangular in outline before, and after, folding and typically hasabout the same length as the stringers 12 in at least one of itsdimensions. The collar 16 includes a peripheral flange 40 that extendsaround the periphery of the collar 16. The peripheral flange 40functions to mechanically hold the lower portion of the sleeve 18 on thecollar 16. The peripheral flange 40 is configured to be folded upwardduring the assembly of the sleeve pallet 10. Typically, the peripheralflange 40 is defined by fold line 42 defined by a crease in or cutpartially through the corrugate sheet 30. As will be recognized by thoseskilled in the art, the partial cutting or creasing weakens fold line 42in the corrugate sheet 30 and allows for more precise folding at desiredlocations. A collar flap 44 is also formed at each corner. The collarflaps 44 extend from one or more ends of the peripheral flange 40. Thecollar flaps 44 are cut along one of the fold lines to allow the collarflap 44 to fold around and secure the peripheral flange 40 in an uprightposition, as illustrated in FIGS. 1 and 2. The collar flaps 44 when theperipheral flange 40 is bent 90 degrees upward at the fold line 42. Thecollar flap 44 is configured to be bent 90 degrees and secured to theadjacent section of peripheral flange 40, which itself has be bent up 90degrees, to secure the peripheral flange 40 in an upright position. Thecollar flap 44 can be secured to the adjacent peripheral flange 40 bytape 48, adhesives, or mechanically using detents and slots or variousother interlocking configurations as will be recognized by those skilledin the art upon review of the present disclosure. In certain aspects,the collar flaps may be secured to the adjacent peripheral flange byvarious metal or plastic fasteners as will be recognized by thoseskilled in the art.

The sleeve 18 is generally designed to contain and/or protect a goodsbeing shipped or stored in sleeve pallet 10. The sleeve 18 can be formedfrom one or more corrugated sheets 30. The sleeve 18 typically definesfour walls 80 when in an open configuration. The sleeve 18 is typicallyopen on both its top portion and bottom portion. The sleeve 18 definesthe peripheral Further, the sleeve 18 is typically collapsible so as totake up a lesser volume and reduce shipping costs during transport tocustomers. In its expanded configuration, the sleeve 18 is typicallyshaped to be received within the peripheral flange 40 and extend withthe flange coextensively with the peripheral flange around the collar16. The outer surface of walls 80 may abut an inner surface of theflange. In certain embodiments, the lower portion of the sleeve 18 maybe secured to the adjacent peripheral flange 40 by adhesives, tapes, ormechanically using detents and slots where the components overlap aswill be recognized by those skilled in the art upon review of thepresent disclosure. The sleeve 18 in combination with the collar 16define the cavity 82 to contain the goods for shipment and/or storage.

As also shown in FIG. 6, a reinforcing insert 84 may be provided on thefloor 84 of the cavity 82 on an upper surface of the collar 16. Thereinforcing insert 84 is typically a flat sheet of material and, incertain aspects, may be an additional corrugate sheet 30 or mayalternatively be a different more durable material to prevent damage toor failure of the collar 18 and/or upper deck 14. If made from arepulpable cellulose based material, the reinforcing insert 84, istypically adhesively secured to the upper surface of the collar 16without compromising the ease of recycling the sleeve pallet 10. If moredurability is needed to protect or reinforce the floor 89 of the cavity82, a non-repulplable material such as metal, plastic, or wood could beused for the reinforcing insert. If a non-repulpable material is used,the reinforcing insert may be loosely fit or compressionally fit betweenthe peripheral flange to enable simple and efficient removal beforerecycling the sleeve pallet 10. Further, such simple fitment and removalpermits the reuse of reinforcing inserts 84 after the useful life of thesleeve pallet 10 has expires. Generally, the reinforcing insert 84 mayhave a shape corresponds to the floor 89 of the cavity or may begenerally coextensive and shaped such that it permits the protectionand/or reinforcement of the floor 89 as would be required for particularapplications and goods. The insert 84 may be adhesively bonded to theupper surface of the collar 16, may be compressionally secured betweenthe peripheral flanges 40 of the collar or may be otherwise removablysecured to the collar 16.

FIGS. 8A and 8B illustrate a top view of a sleeve 18. The sleeve 18 istypically laterally collapsible into a size that can fit onto over thecollapsed components of a pallet sleeve 10 as shown in FIGS. 3 and 4. Ina first embodiment to permit the collapse of the sleeve 18 shown in FIG.8A, the opposing walls of sleeve 18 each include a fold line 58 topermit opposite walls of the sleeve 18 to be folded inward into aflattened four layer folded configuration. The fold lines 58 are locatedsubstantially equidistant from the two corners adjacent to each of thefold lines 58. This spacing allows the inward folding of the opposingsides and the flattening of the sleeve 18. In a second embodiment topermit the flattening of the sleeve 18 shown in FIG. 8B, the ends 68, 69of the sleeve 18 are left unsecured to one another prior to the assemblyof the pallet sleeve 10.

Further as will be recognized by those skilled in the art upon review ofthe present disclosure, sleeve pallet 10 may be further modified to havedesired properties. For example, the components may be wrapped with apaper or plastic or they may be treated at least in part with, interalia, fire retardants, insecticides, pesticides, fungicides, andwaterproofing to inhibit deterioration. Other materials such as metalfoils, plastics, resin impregnated paper, and other fibrous materialssuch as fibrous glass materials could also be incorporated into variousimplementations of the sleeve pallet 10. When the shipping pallet's 10useful life is completed, the sleeve pallet 10 may be disposed of, atleast in part, by recycling.

A cap 20 may be provided to retain the goods and protect the goods fromthe elements. The cap 20 is generally sized and shaped to be receivedover and retained on the upper opening of sleeve 18. When present, a cap20 may be sized to be received over the periphery of the sleeve 18. Thecap 20 is typically formed from a single corrugate sheet 30, similar tothe collar 16. The cap 20 is generally configured to be retained overthe top of the sleeve 18 on the lower surface of the cap 20 and toretain and/or protect the goods on the sleeve pallet 10. The cap 20includes a peripheral cap flange 90 that extends around the periphery ofthe cap 20. The peripheral cap flange 90 functions to mechanically holdthe cap 20 to the upper portion of the sleeve 18. The peripheral capflange 90 is configured to be folded downward during the assembly of thesleeve pallet 10. Typically, the peripheral cap flange 90 is defined byfold line 42 defined by a crease in or cut partially through a corrugatesheet 30. As will be recognized by those skilled in the art, the partialcutting or creasing weakens fold line 42 in the corrugate sheet 30 andallows for more precise folding at desired locations. A collar cap flap94 is also formed at each corner of the cap 20. The collar cap flaps 94extend from one or more ends of the peripheral cap flange 90. The collarcap flaps 94 when the peripheral cap flange 90 is bent 90 degreesdownward at the fold line 42. The collar cap flap 94 is configured to bebent 90 degrees and secured to the adjacent section of peripheral capflange 90, which itself has be bent up 90 degrees, to secure theperipheral cap flange 90 in a downward position. The collar cap flap 94can be secured to the adjacent peripheral cap flange 90 by adhesives,tapes, or mechanically using detents and slots as will be recognized bythose skilled in the art upon review of the present disclosure.

The foregoing discussion along with the Figures discloses and describesvarious exemplary implementations. These implementations are not meantto limit the scope of coverage, but, instead, to assist in understandingthe context of the language used in this specification and in theclaims. The Abstract is presented, for example, to meet requirements of37 C.F.R. § 1.72(b) only. This Abstract is not intended to identify keyelements of the apparatus and related methods of use disclosed herein orto delineate the scope thereof. Upon study of this disclosure and theexemplary implementations herein, one of ordinary skill in the art mayreadily recognize that various changes, modifications and variations maybe made thereto without departing from the spirit and scope of theinventions as defined in the following claims.

The invention claimed is:
 1. An apparatus for the shipping and storageof goods, comprising: an upper deck comprised of a corrugate sheet; aplurality of stringers adhesively secured to a lower surface of theupper deck; a collar comprising a single corrugate sheet defining aperipheral flange, a lower surface of collar adhesively secured to anupper surface of the upper deck; and a sleeve comprising one or morecorrugate sheets, a lower portion of the sleeve received within theperipheral flange of the collar.
 2. An apparatus, as in claim 1, furthercomprising a reinforcing insert positioned on an upper surface of thecollar.
 3. An apparatus, as in claim 2, further comprising thereinforcing insert adhesively secured to the upper surface of thecollar.
 4. An apparatus, as in claim 1, further comprising a capcomprising a single corrugate sheet and defining a peripheral capflange, the cap received over an upper portion of the sleeve.